Door construction



June 1, 1965 J. A. BOHNSACK 3,183,528

DOOR CONSTRUCTION Filed Sept. 17, 1959 3 Sheets-Sheet l INVENTOR.

JOHN A. BOHN SACK ATTORNEYS June 1,1965

J. A. BOHNSACK 3,186,528

DOOR CONSTRUCTION Filed Sept. 17, 1959 3 Sheets-Sheet 2 INVENTOR.

JOHN A. BOHNSACK BY FIG. 5 0M L-/\/\ June 1, 1965 J. A. BOHNSACK 3,186,528

DOOR CONSTRUCTION Filed Sept. 17, 1959 s Sheets-Sheet s (D Q I Ll.

UL .U

/1 E INVENTOR.

JOHN A. BOHNSACK Wd g yM ATTORNEYS United States Patent 6) 3,186,528 DUQR CONSTRUCTIGN John A. Bohnsack, Shaker Heights, Ohio, assignor to The E. F. Hauserman Company, Cleveland, Ohio, a corporation of Ohio Filed Sept. 17, 1959, Ser. No. 840,747 1 Claim. (Cl. 189-46) This invention relates generally as indicated to a door construction and more particularly to a low cost metal door and a method of constructing the same.

- In the construction of metallic doors, such as doors for interior partition assemblies, it has generally been required to seam weld an entire Vertical edge to secure the front and back panel plates together. This lengthy seam weld then has to be ground down and finished to produce a door having a neat appearance. The long lweld method of door construction requires a heavier gauge sheet or a long backup reinforcing member which considerably in-.

creases the amount of metal required in the door and hence the weight of the door. Moreover, the door can not be precoated with a paint or vinyl plastic in that the welding and finishing operation remove-s such coating and requires a further subsequent painting or coating operation.

It is therefore a principal object of my invention to provide a door construction wherein the door will have no externally visible welded seams and which will provide a good looking, neat appearance when completely assembled.

It is another principal object of my invention to provide a metal door construction that will produce a light weight door that can be cheaply and readily assembled.

It is still another object of my invention to provide a door construction wherein the sheet metal employed may be precoated or painted prior to assembly.

It is yet another object of my invention to provide a light-weight, rigid, neat appearing metal door that can be fabricated by simply latching together two panel plate assemblies.

It is a further object of my invention to provide a metal door construction having a fiat, parallel seal interlock that will prevent distortion of the door panels when driven into interlocking position.

I It is a still further object of my invention to provide a novel door frame construction which may readily be assembled with interior panel partitions.

Other objects and advantages of the present invention will become apparent as the following description proceeds.

Tothe accomplishment of the foregoing and related ends, the invention, then, comprises the features hereinafter fully described and particularly pointed out in the claim, the following description and the annexed drawings setting forth in detail certain illustrative embodiments of the invention, these being indicative, however, of'but a few of the various ways in which the principles of the invention may be employed. e

In said annexed drawings; FIG. 1 is an elevational view of an interior partition assembly having a door and frame built in accordance with my invention;

FIG. 2 is a front elevation partially in section of my FIG. 5 is a vertical section on a somewhat enlarged. 'soale taken generally on the line 5-5 of 2 and illustrating top rib assembly;

ice

FIG. 6 is a view similar to FIG. 5 taken on the line 6-6 of FIG. 2 and illustrating my bottom rib assembly;

FIG. 7 is a fragmentary top plan view of my door as shown in FIG. 2; and

FIG. 8 is a horizontal section on a somewhat enlarged scale taken generally on the line 8-8 of FIG. 1 illustrating my door frame construction.

Referring now to the drawings and more particularly to FIG. 1, there is shown a typical interior partition construction which may, for example, comprise a panel 1, a door 2, a transom 3 and a window 4. The various components of the partition may be joined in a manner illustrated in my co-pending application Serial No. 798,491, now Patent No. 3,120,031, and suitable trim strips or post caps 5 and 6 may be used to cover the post connecting means to present a simple clean appearance for the partition wall.

. Referring now to FIGS. 2, 3 and 4, it will be seen that my door comprises two mating panel plate assemblies, designated for example, front panel assembly 7 and back panel assembly 8. It will, of course, be understood that the designations front and back may suitably be interchanged. The front panel assembly 7 includes front panel plate 9 having a rebent edge portion 10 terminating in a latch portion 11 of the general configurationv shown in FIG. 4. The latch portion 11 has a rebent portion 12 on the extreme edge thereof for a purpose later to be described. It will be understood that the portions 10, 11 and 12 of the front plate 9 may extend the entire vertical height of my door.

As seen in FIG. 3, the opposite edge of my front panel plate 9 has a similar rebent portion 13 and a latch portion 14 terminating in a rebent portion 15, which portions are allochirally the same as portions 10, 1'1 and 12 respectively on the opposite edge.

the entire vertical height thereof suitable rebent latch portions. It will, of course, be understood that such re-' bent latch portions may be intermittently spaced along the vertical edges of my door, but I, however, prefer that they extend the entire vertical height of such door.

The back panel assembly 8 includes a back panel plate 16 which, in the embodiment illustrated, is slightly Wider than the front panel plate 9. As seen in FIG. 4, the back panel plate is bent at 17 to form an "end plate 18 which terminates in an inwardly directed flange 19 extending parallel to the edge portion 10 of the front panel plate 9. The' fiange 19 terminates in a rebent latch portion 20. which, as shown in FIG. 4, is designed to mate with the latch portions 11 and 12 of the front panel plate.

As seen in FIG. 3, the opposite end of the back panel plate 16 is bent at 21' to form an end wall 22 which terminates in a'fla'nge 23 extending parallel to the rebent edge portion 13-05: the front panel plate 9. The flange 23 terminates in a rebent latch portion 24 of a configuration to mate with the latch portions 14 and 15 of the front'panel plate." The portions 21, 22,23 and 24 of thezback panel plate 16 are allochirally the same as the portions 17, 18, 19 and 20 on the opposite end of the panel plate. It can now be seen that the back panel plateis bent to form the end of'vertical edge walls of my'door, and these end walls terminate in latch portions designed to mate with suitable latch portions on the end edges of the front panel plate. Thus, the plates 9, 1 6, 18 and 22 form the four sides of my door. In the embodiment illustrated, the end plate portions 18 and 22 are shown as slightly inclined suitably to mate with similar portions of my door frame'construction as will subsequently be described. p 7

My .front panel plate assembly 7 also includes suitably spaced reinforcing ribs of the configuration generallyshown in FIG. 5. The ribs v25 havetwo 1ongi- It will now be seen that both ver-' tical edges of the front panel plate 9 may have extending tudinally extending flange plates 26 and 27 which may,-

for example, be spot welded to the front paneliplate 9. In my illustrated embodiment, I have found that spot welds spaced on three inch centers on'each flange. 26 and 27 are sufiicient rigidly to secure the ribs to the panel plate. Each of the reinforcing ribs has a truncated apex portion 28 designed to mate with similar portion 29 of a rib 30 which is identical in form to the rib 25. The rib 30 is, of course, secured in a similar manner to the opposite plate or in the illustrated embodiment to the back plate 16. If desired, a suitable layer of asbestos or other heat insulated material may be placed between the contacting portions 28 and 29 thereby to render the door of a more fireproof construction. As shown in FIG. 5, there are five'pairs of mating ribs suitablyequal-f' The ribs 31 7 1y spaced along the interior of my door. near the bottom of my doorare slightly foreshortened to accommodate my hinge construction as will hereinafter be described.

Referring again to FIGS 2 and'S, both the frontand back panel plates 9 and 16 are provided at the top portions thereof with mating top ribs assemblies generally shown at 32 and 33. The ribs of these assemblies are generally identical inform to the ribs' 25 and 30 with the exception that the assemblies 32 and 33 include two such ribs interconnected by continuous flanges or plates-: 7 34 and 35 respectively. The rib assemblies 32 and 33 terminate in upwardly extending plate portions 36 and 37 which terminate in inwardy directed flanges 38 and- 39, respectively, which are positioned flush with the top edges 40 and 41 of the panel plates 9 and 16 respectively. As shown in FIG. 2, each top rib assembly 32 and 33 is cutout as shown at 42 and door check reinforcing plates 43 and 44 are secured within such cutout portions to the front panel plate 9 and back panelplate lfirespectively. again, suitably spaced spot welds may be employed to secure the reinforcing plates to the respective panel plates.

The top rib assemblies 32 and 33 are also cutout as 7 shown at 45 to accommodate my upper hinge assembly.

Asseen more clearly inVFIGS. 2 and 4, I provide two. identical hinge assemblies 46 and 47, each of which includes a hinge bracket 48 of the general L-shapedcon figuration shown in FIG. 4 and a hinge reinforcing aspanel plate, thus to provide suitable openings for a lock assembly. The member 58 has a rebent end flange 6i) and a-spacing flange 6.1 on the opposite ends thereof.

This holding or spacing flange has a suitable rebent edge suitable openings in the end plate 22 of my door con-' struction. f

Referring now to FIGS. 2 and 6,1 illustrate the construction of the bottom of my dooryand I employ two mating bottom rib assemblies. The rib 65 comprises an upper plate or flange secureduto the front panel plate 9 as by spot welds and "has an interior "offset portion'67 designed to abutagainst asimilarly ofiest portion 68 on the rib 69 secured to the rear panel plate 16. The lower part of the offset portions 67 and 68 are formed with seatslor shoulders 70 and 71 respectively- The mating seats 70 and 71 are designed to accommodate reinforcing welding plates 72 rigidly-to secure together the bottom of my door construction ina manner hereinafter described. The bottoms of the ribs 65, and 69 terminate in inturncd flanges '73 and 74 which are positioned flush with the bottom edges 75 and 75 ofthe front and back panel plates respectively in a construction similar to that:

for the top ribassemblies 32' and 33. "It is here noted that the bottom channel as well as the check reinforcements are formed in such amanner that'light gauge metal may be employed.

Now referring 't'o my novel method. of assembling my illustrated door, it will be seen thateach of the front and back panel assemblieswillhave secured thereto the reinsembly 49, the, configuration of which is also shown in FIG. 4, The reinforcingassembly '49 includes a vertically extending flange or plate 50 w ih'ch again may be spot Welded to the interior of the front panel plate 9, a'rebent'portion 51 and a hinge plate-52 having suitably spaced clinch nuts 53; secured to the backlthereof.

The rebent portion 51 is, of course, a constructionof the hinge reinforcing assembly permitting it to avoid the latch'portions on the edges of the panel plate assemblies; The hinge bracket 48 may be spot welded to the interior of the back plate 16 as shown at 54 f and the other leg thereof is formed with apertures aligned "with aperturesin the'plate 5210f the hinge'reinforcing assembly. The back panel plate iscutout to* form a mor tise as shown at 56 whereby a hinge' plate maybe sea-q I cured through the plates 55*and 52 as by screws-orbolts. It is noted that when'the hinge leaf is {securedto thehinge assembly, at'ightening ofsuch screws 'with -g in the clinch nuts 53 willtend todraw the plates. 52, f

' 55, and the hinge leaf together thus to form a more rigid hinge construction and further'to secure the front. and

lba'ck' panel plates together. As shown in'FIG. 2, I pro-J vide two hinge assemblies, identical inform, but it will, of course, be understood that three or more may equally well' be provided. 1 Referringnow to FIGS.

is "adapted to be alignedwith a similar. opening :inYthe 2 and 3, I illustrate my lockreinforcing members. Eachpanel plate 9 and 16 is proyided withlock reinforcing members'.;57, and58 respec-, t ively,- which are identical in form. These members may be spot welded m the interior of the' panel plates and j each member may have an opening 59 :the'rein-"whioh 52 of the hinge reinforcing assembly 49lwith the openings,

therein aligned, Further, the lock reinforcing members I Jblies also mate ,to' abut against each other thus-firmly to one vertical edge, preferably the hinge side edge of the two panels together by latching the portionZtl behind the rebent portion 12 of the latch 11 of thefront panel plate.

The panels may be latched together at this vertical edgev by driving the latch portions into engagement until the rebent portion 10 is generally-flush with the end of the back panel plate 16. I V

In order to fasten the opposite vertical edge portion, I

thenbend-slightly outwardly the end wall 22 of the back Wall 18 the latch portion 14-wh-ich will snap behind the rebent portion '15 firmly to secure the front andv back panel assemblies together. It is noted that the gauge of the material employed permits the end Wall 22 of" the back panel plate readily to spring outwardly whereby thelatch portron thereonmay. be driven 'into 'engagement rwith the mating latch portions on thefront-pane-lplate. The door panel assemblies are" now secured together toform the complete door with the various components securedto the assemblies in abutting relationship. Injthis manner, the plate 55 of the hin'ge; brackets "48 vabuts;against theplate mate 'toforma. rigid box-like reinforcing portion for the lassernbly-Lof' the lock:thei' ein.- The ribs and-rib assemreinforce the entire door; Itj i's'notedthat insulation'material may be placedbetweenitheabuttingribs ofmy door constructioriand moreover.that insulation maybe placed 7 or blown ,intothe, opening places between the ribs R furpanel plate 16kand drive the edge latch '24 thereof into ther to produce a heat and particularly sound insulated construction. An example of such insulating material useable with my door construction would be Rockwool.

Now in order firmly to secure the two panel assemblies together, I tack-weld interiorly the four corners of my assembled door as shown generally at 77, 78, 79 and 81) in FIG. 2. This tack-welding may be accomplished through the open top and bottom of my door and such Weld may be a continuous weld approximately 1" long starting about 1" from the top and bottom edges of the door. As seen in FIG, 4, the tack-weld joins the rebent or reentrant portion 12 of the latch 11 with the edge of the rebent latch 20 on the front panel assembly. In FIG. 3, it will be seen that the tack-weld similarly joins the reentrant portion .15 with the tip or edge portion of the rebent latch 24. It can now be seen that the door is rigidly secured together and that no exterior welds will appear thereon.

In order even more firmly to rigidify, the door, I prefer to insert three bottom welding plates 72 in the bottom groove or channel formed by the seats 70 and 71 of the rib assemblies 65 and 69 respectively. These welding or reinforcing plates are provided with central apertures 81 whereby a plugor tack-weld 82 may suitably secure both the rib assemblies together therethrough. As seen in FIG. 2, I provide three such equally spaced reinforcing plates. Each plate may, for example, be provided with two such plug welding holes.

Referringnow to FIGS. 5 and 7, it will be seen that I provide top reinforcing plates 83 and 84- firmly to hold together my top rib assemblies. The reinforcing plates 83 and 84 are identical in form and have beveled edge portions 85 whereby they will clear the latch portions of my plate assemblies. The reinforcing plates are positioned flush with the cutout portions 42 to provide a rigid and firm base for a door check assembly to be mounted on the reinforcing plates 43 and 44. As seen in FIG. 5, the plates 83 and 84 are mounted on suitable angle supports 86 and 87 and are plug welded thereto through apertures 88 in the plates 83 and 84 as shown at 89. The angled members 86 and 87 need only be as long as the reinforcing plates 83 and 84 thereby to support the same and may be spot welded to the upper portions of the first ribs of the top rib assemblies 32 and 3 3. In this manner, the plug weld 89 firmly secures the top rib assemblies to- .gether. It will now be seen that the reinforcing plates 83 and 84 serve the dual purpose of providing door check reinforcements and secuning together rigidly the upper mating top rib assemblies 32 and 33,

Referring now to FIGS. 2 and 3, it will be seen that I provide four tack-welds interiorly of my lock reinforcing members through the circular lock cutout 59. Two vertically spaced tack-welds 90 and 91 join the spacing seat or flange 62 to the opposite lock reinforcing member 57. Similarly, two tack-welds 92 and 93 join the opposite spacing portion to the lock reinforcing member 58. In this manner, the panel plate assemblies are rigidly joined centrally thereof by the box-like configuration of the lock reinforcing members in their mating relationship.

When the hinges are secured to the hinge brackets 48 by threading screws through the apertures therein to engage the clinch nuts 53, 'it will be seen that the panel plate assemblies will also rigidly be secured together at the hinge assemblies. If desired, as many as four screws may be employed firmly to hold each hinge in its respective mortise. In this manner, it will be seen that my illustrated panel assemblies are rigidly welded or secured together by the four corner tack-welds 77, 78, 79 and 811; by the three bottom reinforcing plates 72, tack or plug welded to the bottom rib assemblies; by the top reinforcing plates 83 and 84, .plug welded to the top rib assemblies and by the spaced hinge assemblies when the hinges are secured thereto. Moreover, the entire vertical edge portions of my plate assemblies are driven into latching engagement and the configuration of my latch readily precludes inadvertent or accidental disengagement.

It will be seen that the edges of my door are mechanically interlocked and as a result, they need not be seam-welded or even intermittently welded the entire vertical height thereof. The four tack-welds 77, 78, '79 and 81) are placed internally of the door and, of course, do not show at all but are necessary as pointed out to rigidify the door and to prevent any skewing of the two panel plate assemblies. portions 19 and 23 of the back plate assembly 18 be parallel to the rebent portions 10 and 13 of the front plate assembly7. If they are not, the plates of the door will tend to bulge outwardly or distort when the latches are driven into engagement.

After my panel plates have thus been assembled, the door lock may be inserted in its mortise or opening further to rigidify the door and to complete the assembly thereof. With the hinge leaves in place, my door: is now ready for assembly into the door frame.

Referring now to FIG. 8, it will be seen that my door may be placed in the illustrated door frame construction. The partition assembly may comprise a glass panel secured within an end vertical panel member 101 utilizing a resilient metallic glazing strip 152 in a manner generally similar to that disclosed in my co-pending application Ser. No. 811,094 now Patent No. 3,081,504. Another vertical end member 103 identical in form to the end member 101 may be secured to such end member by a post key 1114 and a suitable post construction may be completed by the insertion of post caps 6 thereon. These post caps snap over the rebent flange portions 105 and 1195 of my vertical end members 101 and 103 respectively in a manner generally illustrated in my aforementioned co-pending applications.

Secured to the end member 103 is my vertically extending door frame or jamb 107. This member is of the configuration illustrated and is secured to the end member 1113 by a suitable retaining washer 108 having a recessed central portion 109 to fit within the enlarged deep channel 110 of the end member 183. The washer may be secured to the end member by a suitable fastening means, as for example, screw 111. The washer overlaps rebent flanges 112 and 113 on the jamb member 107 thus firmly to retain such jamb member against the end member 103.

The jamb 107 is formed with a dovetail groove 114 therein and is adapted to retain a suitable resiliently deformable seal 115 which will abut against the door 2 in its closed position thus completely to seal the opening formed by the door jamb.

As viewed on the left hand side of FIG. 8, the opposite portion of the door jamb is generally allochirally similar in form to the portion just described by the exception that a partition panel 1 is employed in place of the glass pane panel employed on the opposite side of my door. The jamb on the opposite side 116, of course, also employs a sealing strip 117 and it will now .be seen that the jambs 1117 and 116 are slightly inclined thus firmly to mate with the slightly inclined end plate portions of my door construction.

It will, of course, be understood that the door shown in FIG. 8 is broken away and quite foreshortened and that the hinge 118 will readily open and close the door about its pivot. A suitable strike 119, which may be covered with a resilient material, may be employed with the door to control the position thereof when it is closed.

It will now be seen that I have provided a door construction in which the door may be painted before assembly or which may employ vinyl or enamel coated metals for the exterior plates thereof which will not require a further painting or coating operation after my door has been assembled. Moreover, the interior of the door can becompletely painted thus be protected the door from rust or corrosionto provide a long useful It is important that the latch.

life thereforf Thedoor maybe fabricated from thin gauge sheet metal as, for example, steel, stainless steel,

pearance than has heretofore been accomplished in metal door construction.

Further, the mechanical interlocking requires only a minimum amount of metal thus to reduce the weight of the door and provide a cheaper construction. Morevover,

such interior welding or joining of the parts does not appreciablyadd to the weight of the door and does not require'a subsequent grinding or finishing operation. It a will be realized, of course, that a metal-to-metalv bonding resin or adhesive, such as the newer types of epoxy resins, may be employed in place of my tack or plug welding.

Further, with the.

It can now be seen that I have provided a new fornr V i of metallic door construction that will result in a much" neater appearing door and that can be cheaply and easily' manufactured and assembled.

Other modes of apply the principles of the invention may be employed, change being made as regards the details described, provided the features stated in the following claim or the equivalent of such be ernloyed;

I, therefore, particularly point out and distinctly claim as my invention:

In a door construction, a first panel plate assembly v T 3 HARRISON R. M OS ELEY, Primary Examiner.

having laterally directed vertically extending latching grooves adjacent the face thereof, latch portions in said grooves, a second panel plate assembly having end plates extending, substantially normal to the facefof said first panel plate assembly, inwardly directed flanges on the edges of said end plates extending'within said grooves, latch ;portions on said flangesengaged behind the latch portions "in said grooves holding said flanges within said grooves and thus said second panel plate assembly. to said firstpanel'plate assembly, and overlapping angle hinge reinforcing members secured to the respective panel plate assemblies wherebya hinge leaf secured to said members will secure said panel plate assemblies together, the hinge reinforcing'member secured to said first panel .plate being bent to avoid one of said laterally directed vertically extending ,latching grooves.

- ReferencesCited by the Examiner UNITED STATES PATENTS 1,728,964 9/29 Gross 189-.46 11,848,715 3/32 Hart et a1. 189 -46 2,060,608 11/36 Butler. et a1; 189-'-46 2,522,097 9/50 Cookson 189-36 2,579,157 12/51 Priceet al. 189-946 2,664,181 12/53 Boughton 189--46 2,664,182 12/53 Williams et a1. 189-46 2,665,781 1/54 Battles et a1. 189-46 2,696,279 12/54 'Schofield 189-46 2,718,287 9/55 Hobart 18946 2,867,856 1/59 .Cudini 20-11 2,893,070 7/59 Gauthier 20-11 2,948,366 8/60 Kelly et a1. 189-46;

J. D. EEIN, BENJAMIN BENDET'I, Examiners. 

